Miller | KC211335 | Owner Manual | Miller IC User manual

Miller IC User manual
1/
~MiIIer
FORM: OM-148 109
February 1992
Effective With Serial No. KC211335
MODEL:
IHPS4 25-50
IH XFMR4
lc~
ALE COPY
RETUR1\~ TO FOLDER
OWNERS
MANUAL
Read and understand the entire contents of this manual, with
special emphasis on the safe~ material throughout the manual, before installing,
operating, or maintaining this equipment This unit and these instructions are for
use only by persons trained and experienced in the safe operation of induction
IMPORTANT:
heating equipment. Do not allow untrained persons to install, operate, or maintain
this unit. Contact factory if you do not fully understand these instructions.
coven
1/92ST.151
874
MILLER ELECTRIC
A MISer
Group
Ltd.,
Mfg. Co.
Company
~ BOX 1079
WI 54912 USA
Tel. 414-734.9821
Appleton,
PRINTED IN USA
I
L
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
This warranty supersedes all
previous MILLER warranties
LIMITED WARRANTY
Subject
and is exclusive with
to the terms and conditions
hereof, MILLER Electric Mfg. Co. Appleton. Wisconsin war
rants to its Distributor/Dealer that all new and unused
Equipment furnished by MILLER is free from defect in
workmanship and material as of the time and place of delivery
by MILLER. No warranty is made by MILLER with respect to
engines, trade accessories or other items manufactured by
others. Such engines, trade accessories and other items are
sold subject to the warranties of their respective manufacturers,
if any. All engines are warrantied by their manufacturer for two
years from date of original purchase, except Deutz engines
which have
a one
year, 2000 hour warranty.
Except as specified below, MILLERs warranty does not apply
components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points.
MILLERMATIC parts that come in contact with the welding wire
including nozzles and nozzle insulators where failure does not
result from defect in workmanship or material.
no
other
guarantees
or
warranties
expressed
or
implied.
In the case of MILLERs
breach of warranty or any other duty
quality of any goods. the exclusive remedies
therefore shall be, at MILLERs option (1) repair or (2) replace
ment or, where authorized in writing by MILLER in appropriate
cases, (3) the reasonable cost of repair or replacement at an
with
respect
to the
authorized MILLER service station
or
(4) payment of
or
credit
for the purchase price (less reasonable depreciation based
upon actual use) upon return of the goods at Customers risk
and expense. MILLERs option of repair or replacement will be
FOB.. Factory at Appleton, Wisconsin, or FOB. at a MILLER
facility, therefore, no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure. MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
authorized service
to
MILLER shall be required to honor warranty claims on war
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of
Equipment to the original user:
Arc welders, power sources, robots, and
1.
1
year
components
2.
Load banks
3.
Original
4.
All
5.
All other MILLERMATIC Feeders
6.
Replacement
7.
Batteries
(labor 1 year only)
welding guns, feeder/guns
or
As
a matter
by
and torches
.
.
.
90 days
.
1 year
repair parts, exclusive of labor.
60 days
6 months
provided that MILLER is notified in
of the date of such failure.
submitted
1 year
3 years
main power rectifiers
of
writing
within
thirty (30) days
general policy only, MILLER may honor claims
original user within the foregoing periods.
the
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS
PROVISION. MIGHT ARISE BY IMPLICATION. OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING.
INCLUDING ANY IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOP PARTICULAR PURPOSE.
WITH
AND
ALL
ANY
RESPECT TO
EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
WRITING,
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS
WARRANTIES DO NOT
EXTEND TO. AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLERS WARRANTIES TO, ANY CONSUMER.
RECEIVING-HANDLING
Before
unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for
damage with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or
equipment manufacturers Transportation Department.
loss or
When
requesting information
about this equipment,
Use the
the
always provide Model Designation
following spaces to record Model Designation and Serial
rating label or nameplate.
or
Style
and Serial
or
Style
Number.
Number of your unit. The information is located
on
Model
__________
Serial
or
Style
No.
Date of Purchase
m,IIe, 8191
INDUCTION HEATING SAFETY PRECAUTIONS
Below
are
Keep all labels readable. If any label is unreadable or
damaged, order replacements free of charge by calling
examples of the precautionary labels found
power source, the controller, and the head
assembly. Any person who installs operates, maintains,
or services this equipment must know and follow all
on
the
occupational safety practices
the precautions on these labels.
applicable
well
as
codes and
414-735-4356.
as
INDUCTION HEATING
WARNING
Do Not Remove,
ELECTRIC SHOCK
can
Keep children away.
INDUCTION HEATING
kill.
Watch for fire;
Disconnect input power before servicing.
Keep
all
panels
and covers
INDUCTION HEATING
burns.
Do not touch
or
can cause
fire.
Do not overheat parts and adhesive.
Do not touch live electrical parts.
S
be hazardous.
Manual carefully.
Only qualified persons are to Install, operate, or service this
unit according to all applicable codes and safety practices.
This Label.
Destroy, Or Cover
can
Read and follow this label and the Owners
securely
in
injury
can cause
handle induction head
keep extinguisher nearby.
Do not locate unit
~
or
over
combustible surfaces.
FUMES AND GASES can be hazardous
to your health.
during
operation.
Keep metal ~eweiry and Other metal personal
Items away from head during operation.
Allow cooling period before handling parts.
Properly ventilate work
area.
Read Material Safety Data Sheets (MSDSs) and
manufacturers Instructions for material used.
Read NFPA Standard 70, NatIonal Electrical Code, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
and CSA Standard C22.1, Canadian Electrical Code Part 1, from Canadian Standards Association, Standards Sales, 17$ Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
I
a AVERTISSEMENT
7\
UN CHOC ELECTRIQUE
peut
etre mortel.
CHAFFAUGEPARINDUCTIONpeutetrehasar.
deux.
Installation et raccordement de cette machine
dolventetreconformesatouslescodespertlnents.
Figure
Lire Ia manuel dlnstructions
No poe Installer
cur une
avant utillsation.
surface combustible.
S.147 876
1. Power Source Label
a WARNING
INDUCTION HEATING
can cause
injury
burns.
or
Do not touch or handle Induction head
during
operatIon.
Keep metal leweiry and other metal personal
Items away from head during operation.
Allow
coolIng period before handling parts.
9.147 818
Figure
2. Induction Head Label
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical
parts.
Input power before main
taining or servicing.
Keep all covers, guards, and panels
DIsconnect
securely In place.
Figure
3. Controller Label
SR9_7191
TABLE OF CONTENTS
SECTION 1
SAFETY SIGNAL WORDS
1
SECTION 2
SPECIFICATIONS
1
SECTION 3
INSTALLATION.
2
3-3.
Installing Induction Head
Installing Transformer
Connecting Coolant Supply
4
3-4.
Remote Control Connections
4
3-5.
Connecting Input
3-1.
3-2.
Power
SECTION 4OPERATION
3
5
7
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
9
5-2.
Overload Protection
10
5-3.
Troubleshooting
10
SECTION 6
ELECTRICAL DIAGRAMS
SECTION 7
PARTS LIST
Figure
Figure
7-1.
Complete Assembly
7-2. Transformer & IC Induction Head
11
14
17
OM-i48 109- 2/92
SAFETY SIGNAL WORDS
SECTION 1
i~Od1
The
following safety
alert
symbol and signal words
are
used
throughout
this manual to call attention to and
I
9~9
identify
different levels of hazard and special instructions.
WARNING
a
WARNING statements identify
inlury
or
procedures
a
or
practices
or
practices
which must be followed to avoid serious
personal
CAUTION
procedures
equipment.
CAUTION statements identify
injury
or
loss of life.
damage
to this
~ IMPORTANT: statements
which must be followed to avoid minor personal
identi& special instructions necessary
SECTION 2
for the most efficient operation of this equipment.
SPECIFICATIONS
4
1
Power Source
2
Transformer
3
Head
4
Heating Surface
3
2
S1~15I 874
Figure
2-1. Induction
Heating System
OM~148 109
Page
1
Table 2-1. Induction
Heating
Power Source
Description
Specification
25 To 50 kHz
Type Of Output
Rated
Three-Phase, 230 Or 460 Volts AC, 50/60 l-lz
Type Of Input Power
Input Amperes
Duty Cycle
4 kW At 100%
Output
At Rated
KVA Used At Rated
KW Used At Rated
Output
Output
Output
20 Amperes At 230V; 10 Amperes At 460V
7.1 kVA
4.8 kW
Overall Dimensions
Length: 16-112
Weight
Ship: 43
lbs.
in.
(419 mm); Width:
(20 kg);
Net: 38 lbs.
Table 2-2. Induction
11-1/2 in.
(298 mm)
Heating
Transformer
Description
4 kW
Output
10 ft.
(3 m)
Overall Dimensions
See
Figure
Weight
Ship:
Cable With
in.
(17 kg)
Specification
KW
(292 mm); I-Ieight: 11-3/4
Plug
3-2
10.5 lbs.
(4.7 kg); Net: 6.5 lbs. (4 kg)
Table 2-3. Induction
Heating
Head
Description
Specification
Overall Dimensions With Adjustable
Bracket
Length:
Weight
Ship:
5 in.
4 lbs.
(127 mm); Width: 2-1/2
in.
(64 mm); Height: 5-1/4
in.
(133 mm)
(2 kg); Net: 2 lbs. (0.9 kg)
SECTION 3INSTALLATION
3-1.
Installing
Induction Head
3
4
1
Induction Head
2
Adjustable Bracket
3
Screw
4
Washer
Install brackets onto head
hardware shown.
5
Screw
6
Self-Locking
7
Transformer Bracket
using
Nut
Install head onto transformer
hardware shown.
To
change position
screws, move
7
using
of head, loosen
head, and tighten
screws.
Torque
screws
on
head
to
50
in.-lbs.
Tools Needed:
7/16in.
ST-151 006-A
Figure
3.1. in stalling induction Head
3-2.
A.
Installing Transformer
Transformer Dimensions
Inches
Millimeters
9.3/4
248
8
7-12
191
C
2-7/8
73
0
4-3/8
111
E
6
152
A
E
I
I
Ret. SA.147 261
Figure
B.
Connecting
3-2. Transformer Overall Dimensions And
Mounting
Hole
Layout
Transformer To Power Source
1
2
3
4
~r---~
1
Transformer
2
lOft. (3m)
Cord
3
Plug
4
Keyway
5
Rear Panel Of Power Source
6
4-Socket Receptacle RC8
Interconnecting
To connect pug to receptacle, align
keyway, insert plug, and tighten
threaded collar.
=
0
Or
LJ
ST-ISO 151-A
Figure
3-3. Transformer Connections To Power Source
OM-148 109
Page
3
Connecting Coolant Supply
3-3.
WARNING
a
OVERHEATING
can
damage
INCORRECT COOLANT FLOWRATE
coolant system and head.
induction head.
using recirculating
system, do not make connections
from coolant system to water valve; instead make connections
directly from coolant system to induction head hoses.
If
coolant
Maintain I
qt/min (1 Lmiri)
can
damage
coolant flowrate at all times.
Tools Needed:
2
I
Coolant
Install hose ends onto either
Supply
2
Induction Head Coolant
Pipe
4
Hose
ant
fittings
supply fittings.
6
Coolant
Install proper
Coolant Hose, 1/4 in. (6 mm) Inside Diameter
Obtain hoses long enough to connect head to coolant
I
supply.
Figure
3-4.
on
head. Secure with
Fittings
5
Clamp
Obtain hose clamps.
3
pipe
clamps.
Obtain and install coolant supply.
onto hoses. Connect hoses to cool
Supply Fittings
qtimin (1 Ljmin) coolant flow
3-4. Connections To Coolant
rate
required.
ST-150 755
Supply
Remote Control Connections
I
Plug
2
Threaded Collar
3
Keyway
4
9-Socket Receptacle RC9
5
Rear Panel Of Power Source
To connect to receptacle, align key.
ways, insert plug, and tighten
threaded collar.
Socket lnformat~on:
S
1
4
2
3
+15 volts dc output with respect to circuit common.
Contact closure between sockets 1 and 2 energizes
power source.
0 to +10 volts dc signal for power source frequency
control.
4
Circuit
5
0 to +10 volts dc
6
0 to +15 volts dc
control device.
common.
7
Circuit
8
Not used.
9
+
signal for power source output control.
signals power source failure to remote
common.
10 volts dc output with respect to circuit
common.
Ref. 5.0645/ Ref. 5.0628 / Ref. ST. 150 751-A
Figure
3-5. 9-Socket
Receptacle Connections
3-5.
Connecting Input Power
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn OFF power
Have
source,
only qualified
and disconnect
input power before inspecting
installing.
or
persons install unit.
Installation must meet National Electrical Code and all other codes.
A.
Positioning Jumper
a
WARNING
swarn31
10191
Links
ELECTRIC SHOCK HAZARD. Read
fore proceeding.
safety
information at
beginning
of Section 3-5 be
Turn OFF unit POWER Switch.
Jumper links allow operation on dif
ferent input voltages and are facto
ry set for the highest input voltage.
Check input voltage available at
site.
230
d
460
1
Terminal
Strip TE2
2
Terminal
Strip TE3
3
Input Voltage Jumper
4
Input Voltage
230
~d~~6
APPLIES TO 80TH 1E2 AND TE3
S-ISO 944
Look at
link
Link
Label
jumper links and compare
position with label.
Move links to match input voltage.
For example, use 230 volts posi
tion on label when 230 volts
input
power is available.
Reinstall and
secure
wrapper.
Tools Needed:
Ret ST-ISO 781
Figure
3-6.
Input Voltage Jumper
Links Location
OM-148 109 Page 5
B.
Connecting Input
a
WARNING
Power
ELECTRIC SHOCK HAZARD. Read
fore proceeding.
safety information
at
beginning
of Section 3-5 be.
Turn OFF unit POWER switch.
Input Conductors
1
Select size
Table 3-1.
and
length
using
Three-Phase Line Disconnect
Switch
2
Obtain and install switch.
Grounding Conductor
3
size and length using
Table 3-1. Be sure ground conduc
Select
tor goes to an earth
6
ground.
4
Input Terminal Block
5
Ground Terminal
Connect input conductors to termi
nal block and grounding conductor
to
ground terminal
Connect
input
in power source.
conductors
and
grounding
gized
Conductor to deener
line disconnect switch.
Line Fuses
6
Select fuses or circuit breakers us
ing Table 3.1. Install into deener
gized
line disconnect switch.
Connect
deenergized supply
con
ductors to line disconnect switch.
Place line disconnect switch in ON
before
using power
position
source.
Figure
3-7.
Input Power Connections
Table 3-1. Electrical Service
Requirements
Input Voltage
input Amperes
At Rated
Circuit Breaker Size
Output
Range
Amperes2
Input Conductor Size
Length
Grounding Conductor Size
In
are
AWG/KcmiI5
~
9
25
15
12
14
138
359
(42)
(110)
12
14
calculated from the 1990 edition of the National Electrical Code (NEC).
Circuit breaker range is 150% to not
source (Article 630-12(a) of NEC).
2
18
In
Maximum Input Conductor
in Feet (Meters)4
These values
460
36
AWG/Kcmll3
*
230
In
Amperes
Fuse Size In
ST-15O76~
more
than 200% of rated
Standard fuse size is that closest to 150% of rated
630-126 of NEC).
input amperage of
the
welding
power
input amperage of the welding power source (Article
Input conductor size is for insulated copper wire with 75C rating with not more than three single current
a cable or raceway (Article 630-16 of NEC).
carrying conductors in
~
Maximum length is to prevent more than a 3% voltage drop between service entrance and
nals of the welding power source (Articles 210-19(a) and 215-2(b) of NEC).
~
The grounding conductor shall be colored or identified as specified In the NEC. Grounding conductor
size for copper wire is not required to be larger than input conductor (Article 250-95 of NEC).
input termi
~
OM-148 10
~qe
6
SECTION 4- OPERATION
WARNING
a
ELECTRIC SHOCK
INDUCTION HEATING
can kill.
Do not touch live electrical parts.
Disconnect input power before servicing.
Keep
all
panels
and covers
INDUCTION HEATING
or burns.
securely
in
Watch for fire; keep
place.
Do not locate unit
or
combustible surfaces.
injury
can cause
handle induction head
during
Allow
can
be hazardous
to your health.
operation.
Keep metal jewelry and other metal
away from head during operation.
fire.
extinguisher nearby.
over
FUMES AND GASES
Do not touch
can cause
Do not overheat parts and adhesive.
Properly
personal items
ventilate work
area.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
cooling period before handling parts.
1
2
Power
Adjustment Control
Frequency Adjustment
Control
3
Remote
Power/Frequency
Adjustment Switch
4
Power Switch
Ref. ST.f 51 574
Figure
4-1. Controls
2
1
~
1
Insulating Gloves
2
Safety Glasses
With Side
Shields
Wear
dry insulating gloves and
safety glasses with side shields.
sb3.1
Figure
4-2.
tO/91
Safety Equipment
1
Power
Adjustment Control
Use control to select power be
tween the minimum and maximum
output of the power source. The
numbers around the control are for
reference only.
Ret ST.147 386.A
Figure
4-3. Power
Adjustment Control
OM-148 109
Page
7
1
Frequency Adjustment Con
trol
Use control to select frequency
output between 25 and 50 kilo
hertz. To obtain maximum heat out
put, select frequency that matches
rating of induction head.
Figure
4-4.
Frequency Adjustment Control
Remote
I
Power/Frequency
Adjustment Switch
Use switch to select way of
unit Output.
con
trolling
For front panel control, place
switch in PANEL
position.
For remote control, place switch
in the REMOTE 9 position.
Figure
4-5. Remote
Power/Frequency Control Switch
I
Coolant
Turn
on
Supply
coolant
supply before
heating.
Turn off coolant
ished heating.
supply when
fin
eQe~
Ref. ST.150 755
Figure
OM-148 109 Pa~:e 8
4-6. Coolant
Supply
Power Switch
I
Use switch to turn unit, fan motor,
and pilot light ON and OFF.
2
Unit is
ter
ready to heat
10 seconds af
POWER Switch is placed in the
ON position.
Pilot
2
Figure
\
Conn~ )
~)
)
Install &
I Induction
,
Heating
Equipment
4-7. Power Switch
~) )
Turn On
Coolant Supply
Put On
Personal Safety
Equipment
Light
~
Position
Near Head
Set
Controls
Heating
Surface}
Swit
_________________
_________________
Unit Ready
To Heat
Wait
10 Seconds
Figure
4-8.
)
Sequence Of
Induction
Heating Process
SECTION 5- MAINTENANCE & TROUBLESHOOTING
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
INDUCTION HEATING
kill.
can cause
injury
or burns.
parts.
Do not touch
Disconnect input power before servicing.
or
handle induction head
during
operation.
Keep
all
panels
and covers
securely
in
place.
Keep metal jewelry and other metal personal items
away from head during operation.
Allow
cooling period before handling parts
Maintenance and
troubleshooting
to be
performed
only by qualified persons only.
5-1.
Routine Maintenance
Table 5-1. Maintenance Schedule
Time
Before each
Every
use.
month.
Maintenance
Clean copper surfaces between transformer and head.
Above normal equipment
use: Check all labels (see 6 month entry), repair any
replace cable, repair any breaks or clogs in coolant
hoses, clean internal parts (see 6 month entry), clean and tighten connections.
damaged
insulation
or
Every
3 months.
Repair any damaged insulation or replace cable, and repair any breaks
in coolant hoses. Clean and tighten connections.
Every
6 months.
Replace any labels that are unreadable or damaged (see Section 7 for part
number). Blow out or vacuum dust and dirt from inside using a clean, dry air-
or
clogs
stream or vacuum suction.
OM.148 109 Page 9
5-2.
a
Overload Protection
WARNING
S
ELECTRIC SHOCK AND INDUCTION HEATING HAZARDS. Read safety information at
beginning
of Section 5 before
proceeding.
protects the unit from damage due to overheating. If main heat sink gets too hot, TP1 opens and output
keeps running to cool the heat sink. Wait several minutes before trying to heat.
Thermostat TP1
stops. The fan
5-3.
a
Troubleshooting
WARNING
ELECTRIC SHOCK AND INDUCTION HEATING HAZARDS. Read
beginning of Section 5 before proceeding.
Table 5-2.
safety information
Troubleshooting
Section
Remedy
Trouble
Replace building line fuse
No heat output.
Secure transformer
plug
or
reset circuit breaker.
in power source
receptacle.
3-5
3-2
Check and replace POWER switch Si if necessary.
No heat output; fan motor
tinues to
run.
Low heat output.
con-
Thermostat TPI open (overheating). Allow fan to run; the thermostat will close when the unit has cooled.
5-2
Connect power
line voltage.
3-5
source to
proper input
voltage
or
check for low
at
SECTION 6- ELECTRICAL DIAGRAMS
230/
460
p
SI
I
2
PCG
CR
//
<
506-5
505-5
12
~ 501-2
PCI
PC I /PLG I
5C2/Pt.02
PC3/PLG3
RC4/PLG4
505-2:
505-I
RC5/PLGS
5C6/PLG6
509
5C7/PLG7
/2
PC 1-6
4
6
~
PCI-I
~
~
7>
9
504-9:
501-9
<< PCI-C
>
901-10
504-7
504-6
9C4-2:
PC
1-14
904-I
504-4
PCI-Il
502-2
PCI -13
507-2
907-3
P03-I
P02-I
PCI
3_
0~
-
I 2
PCY-
I
PEp~rE
PC,-
SC.145 4340
Figure
6-1. CircuIt
Diagram For induction Heating Power Source
OM-148 109
Page
11
a
~OILI~OIL2~
GND
TE
230 460 230
TE3
L3~
8A(SI -601)
L2fifi
74(SI -MID)
LI~S
64(Sl -TOP)
1
14
230 460 230
TE2
WI
~I__
LI~I.~c1~j
~
UI
UI
UI
U
~
~
_____
(TI
W
COIL
2-2)
z
I7AITP I-TOP)
W
I~3
I
tg
0
~
-
-~~
264)Pt.GI-9
AS4RED~T2
PM
PEO)PLG5-Ii)~3
LGS-6)
~
I
74)609-2
I
0
(
C2
RC9
24(S)
4C3
T~
Ad
42C(Pt.GI -6)
I
~o~oJ
ASICI
I
04
I
WHITE
p~15)
I
03
L
W1IITE
-~
I
2)003
536(C)
~OB4
&26(P(..GI-I)
tj -6
L
-/
(
___
.
4~(I4AT SIM( GPO
-
05
PC3
CT2
T2
I
-Co
06
0
Io~o~ioi-o
jj:J
~!1
WWT(PIG4-4
I
IFC2
ZI
(COIL
_________
I
121
PC2
I~I
_________
SI
RZO)PtG4-I(
2QA I R4-LF FT I
-
0WHT)P1135-I
________
W#IflPIG4-2)
*4T)P1135-6)
___________
r
TI (COIL
2-4)
AC) p
-
I
091
I
RED
02
L
420(GPO
~
2-2)
_________
~.
I I
I I
IL I
-2)~ ~
(COIL
___________
-~OOI
I
ZI
ui.iT (
TI
28(RCe-6)
PED(P1137-4
J
TI
56*
~~~42A(P1GI-2
--
LI
I
D5
DC
DC
~5A
BACK
PC4
I
~
CflTTI
39A(S2 6)
CASE
G~D
04
L
9l~ 2
EAT
OSI~1~
GPO
TI(COIL
-4)
ASIO
I
(
~_5O8)C2)061
AC21
D8J
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i~
~--~
-
~TE,
INST~L C12 WITh
9EGI~4IPG F*CIPG 603
rIffl~4I
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RC8
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I
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P104
PC5/p~IUl~
___________
P1G5liI~IiUi~i~i
L~J ~
__
__________
J~J
WI4T)06-GI
28 (PC~-T I)
604i
I
j
W(4T(06-132)
~ci
607/
~1~J
P1137
W~.IT(PC4
PE~P~-TI
27)604)
~i
WHT )CT2)
602/
711
P102
AIA(TPI -901)
24A(SPIICE
~LS.IcZ
EL)
32A(62-CCW)
TEL)
~
~I~I
IOA(CPI-A
Pd
_________
WHTccTI)
WWTICTI I
Figure
OM-148 109
Page
12
I
RED
30A)66-RIGHT
6-2.
Wiring Diagram
For Induction
r1pc3
~P1G3
Heating
RC6/
~
II3c1~
P101
TFb136
Power Source
________
U) a
0
0 (0
0
w (0 0
a CD 0 9 0
C.)
PARTS LIST
SECTION 7
C.,
C.,
cJ
C.,
I,
(I,
(f,.
0
ce,.
c~J
c~J
C~J
/
/
I
/
C.,
/
I
is)
C.,
/
/
/
cJ
c~J
/
/
/
.0
E
4,
U)
4
a,
4)
_
4)
0.
E
0
0
4)
I
LI.
C.,
C1
U,
U,
U,
U,
IM.148 109 Pace 14
Replace Coils
Factory Or Factory Authorized Service Station
Part
No.
Dia.
Item
No.
At
Mkgs.
Description
Figure
141 690
1
.
.
2
.
.
PCi
PLG1
..
PLG2
..
.
..
.
.
.
.
150900
131 056
..
.
.
PLG5
.
.
.
.
.
PLG6
.
.
.
PLG7
..
.
.
.
.
.
131 054
4
..
.
.
TE2,3
.
.
.
115 091
113746
130 203
113 746
.
.
.
.
.
..
.
.
.
..
.
.
.
..
.
.
115093
..
113 746
.
115 094
..
113 746
147 507
038 081
601 219
3
..
..
115 092
113746
PLG4
..
113 746
113 746
PLG3
..
.
.
.
.
.
.
..
7-1.
Complete Assembly
GROMMET, scr No. 8/10 panel hole .281sq .197 high
CIRCUIT CARD, control
HOUSING RECEPTACLE & SOCKETS, (consisting of)
4
TERMINAL, female iskt 24-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female iskt 24-18 wire
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt24-l8wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt24-l8wire
HOUSING PLUG & SOCKETS, (consisting of)
14
.
.
.
.
TERMINAL, female lskt 24-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
INSULATION, PC card
.
.
PC4
..
.
.
.
8
9
10
11
.
..
RC8
.
.
.
..
..
RC9
.
.
.
.
.
.
CT2
..
.
..
.
..
17
..
18
..
19.
20
.
.
..
.
..
PC2
CT1
.
.
..
.
.
21
22
23
24
25
26
.
.
..
.
.
.
.
.
..
.
.
.
.
.
..
PC3
.
.
.
Q5,6
.
.
.
.
.
.
VR1-3.
.
.
.
.
TPI
SRI
..
094 517
..
146 951
..
30
148 828
..
.
.
34
.
.
.
35
.
.
.
Q1-4
.
05,8,9
.
.
.
.
146932
000 366
132 951
131 467
147 947
010 913
601 835
.
.
.
.
.
.
..
..
TEl
Zi
..
...
.
.
.500
CIRCUIT CARD, bus connect
..
..
.
x
..
119 757
.
SCREW, mach brs trh 10-32
132 843
TRANSISTOR, IGBT module 75A 600V
032 810.. THERMOSTAT, NC
090 304
VARISTOR, 220 joule 73OVDC
29
FM
1
1
1
1
..
..
..
.
1
3
I
145 689
.
.
1
9
..
28
33
.
.
I
..
36
37
38
.
1
..
..
.
I
..
128 803
32
.
.
131 828
31
1
4
1
27
.
4
4
.
16
1
2
..
..
15
1
..
..
14
12
4
..
.
I
10
.
..
13
1
2
6
BLOCK, term 20A 4P
LINK, jumper term blk 20A
145 453
BRACKET, mtg PC board
133 405
NUT, speed 10-24 rectangular
CIRCUIT CARD, capacitors
146 955
151 022
INSULATION, PC card
098 691
STAND-OFF, No. 6-32 x .500 Ig .25Ohex
148 118
RECEPTACLE, twlk flange mtg 4skt
147 820
HOUSING RECEPTACLE & SOCKETS, (consisting of)
079 534
TERMINAL, female iskt 18-14 wire
149 256
TRANSFORMER, current
126 026
LABEL, warning electric shock can kill
+151 011
WRAPPER, w/insulation (consisting of)
151 010
STRIP, ppr 100% rag .020 x 4.500 x 10.000
128415.. CLAMP,saddle
126 416
HANDLE, molded
147 876
LABEL, warning general precautionary
144 483
CIRCUIT CARD, interconnecting
150 925
TRANSFORMER, current
..
12
1
8
.
..
7
1
1
.
..
.
Quantity
..
..
..
..
..
..
.
.
147 386
..
145 692
..
146 946
..
RECTIFIER, integ 100A 1200V
BAR, support heat sink top
HEAT SINK, power module
BAR, support heat sink bottom
BRACKET, mtg tan motor
MOTOR, fan
RING, retainer E .250 shaft grv x .O2Sthk
BLADE, 6.5 in 6wg .250 bore CW
TRANSISTOR, mosfet 45A 500V
DIODE, fast recovery 30A 800V
WASHER, flat brs .218 ID x .46000 x .O3lthk
NUT, brs hex 10-32
BLOCK, term 70A 3P
CASE SECTION, front/bottom/rear
STABILIZER
1
4
1
2
1
3
1
1
1
1
1
1
2
1
4
3
10
6
1
1
1
OM-148 109 Page 15
Item
No.
Dia.
Part
No.
Description
Quantity
-
Mkgs.
Figure
39
146976
40
146975
146974
141 422
42
.43....
R5....
44....R3,4
R6....
..46....CR1...
.45....
141 424
139203
144656
106462
019663
47
48
..49.,..PL1....
.
52
149338
097922
006 426
53
136190
54....C1,2
55....R1,2
124696
073 562
57
099 037
51
091 441
+When
7-1.
Complete Assembly (Continued)
TRANSFORMER, pwr main 325V (consisting of)
COIL, pri/sec 325V RH
COIL, pri/sec 325V LH
INSULATOR, flat pack
RESISTOR,
RESISTOR,
RESISTOR,
RELAY, end
Page
16
1
1
1
WW fxd 30W 25 ohm
1
WW fxd 30W 8K ohm
2
WW fxd 30W 20K ohm
24VDC DPDT
MOUNT, nprn 15/16 OD x 3/8rec 3/16 x 3/8
NAMEPLATE, (order by model and serial number)
LIGHT, md red lens 28V
SWITCH, rocker DPDT 4A 25OVAC
KNOB, pointer .875dia x .250 ID
CLAMP, capacitor
NUT, speed U type 10-32
CAPACITOR, elctlt 1 700uf 400VDC
POTENTIOMETER, C sltd sit l/T 2W 10K ohm
SWITCH, tgl 3PST 40A 600V
EDGE TRIM, style 62-1/16 black w/clips (order by ft)
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-148 109
I
1
1
4
1
1
1
2
2
4
.2
ift
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
1
147740
2
148119
3
5
148120
+147256
147878
6
150643
4
7
147739
8
147273
7-2.
Quantity
Transformer & IC Induction Head
TRANSFORMER, induction (consisting of)
PLUG, twlk 4 pin
CONNECTOR, conduit flexible
I
1
...
.
.
.
COVER, induction head
LABEL, warning high magnetic field
.
1
BRACKET, adapter IC head
HEAD, induction heating (consisting of)
SHEET, polyest gi lam .031 x 1.250 x 4.312
1
2
1
1
6
7
81.151 118
FIgure
7-2. Transformer & IC Induction Head.
+When
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
011-148 109
Page
17
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